Connector

ABSTRACT

An improved connector comprising, in one embodiment, an extrudably deformable hollow metallic inner member disposed within a suitably orificed extrudably deformable insulating outer member, said members being selectively adapted for extrudable constriction about the free end of one or more conductors inserted within the inner member, as said connector is forcibly urged through a preferably successively restrictive orifice, resulting in an essentially sealed insulated assembly. The inner member may be formed of hollow stock, appropriately wound elongate material, or annular elements in stacked arrangement.

0 United States Patent 11 1 1111 3,739,470 Eppler 1 June 19, R973 CONNECTOR 3,010,183 ll/l96l Forney, Jr. 29/630 F [7 Inventor: a e pp Elizabeth, J 3,064,072 ll/l962 Graff et al. 29/630 F Assigneei Tllomas & Belts Corporation, Primary ExaminerCharles W. Lanham El Za t N- Assistant Examiner.lames R. Duzan [22] Filed Sept 16 1971 Attorney-David Teschner and Jesse Woldman et al.

[2]] Appl. No.: 181,008 ABSTRACT An improved connector comprising, in one embodi- [52] 29/628 ment, an extrudably deformable hollow metallic inner [51] i t i 43/00 member disposed within a suitably orificed extrudably [58] i 55 203 deformable insulating outer member, said members 29/203 D, 203 DT, 628, 629, 630 R, 630 A,

being selectively adapted for extrudable' constriction about the free end of one or more conductors inserted within the inner member, as said connector is forcibly urged through 21 preferably successively restrictive ori- [56] References Cited flce, resultmg 1n an essentlally sealed 1nsulated assem- UNITED STATES PATENTS bly. The inner member may be formed of hollow stock, 2,429,585 10/1947 Rogoff .1 29/630 F appropriately wound elongate material, or annular ele- Hollzapple A ments in stacked arrangement 2,954,420 9/l960 Logan 29/630 F 2,965,147 12/1960 Hoffman 29/630 F 4 Claims, 11 Drawing Figures I magmal l A 22 32 'l/l/l/ PAIENTEDJIIN 1 9% V 3. 739.470

NVENTOR.

1G. 6' DANIEL EPPLER BY 3 Q AGENT CONNECTOR BACKGROUND OF THE INVENTION 1. Field of the Invention The invention is directed to the field of connectors, and principally to deformable connectors for sealably joining electrical conductors or similar articles.

2. Description of the Prior Art Connectors according to the prior art generally comprised an outer sleeve within which was suitably disposed a hollow inner ferrule adapted to receive therein the bared ends of electrical conductors or the like. In order to establish a connection between said conductors, the bared ends thereof would be inserted within the hollow inner ferrule. The connector would then be placed between the jaws of a compression tool whereby the connector would be subjected to an inwardly directed radial compressive force. The material comprising both the inner ferrule and the outer sleeve would thus be unevenly distributed circumjacent the conductors disposed therewithin. Additionally, the bared ends of the conductors were subjected to uneven forces, resulting in a high probability of damage thereto. Because of the damage which may be encountered by the conductors within the connector, the security of retention therein was generally degraded, thereby substantially decreasing the force required to separate the protective connector from the conductors therein. Further, because the crimp area is generally selected substantially centrally of the longitudinal dimensions of the connector, the open end of the connector would tend to flare outwardly, directly adjacent the opening through which the conductors had been inserted. As a result thereof, the orifice into which the bared ends of the conductors had been inserted was at least partially exposed to the environment, subjecting said ends to adverse environmental attack. Further, as a result of the substantially radial force applied to the connector by means of the jaws of the crimping tool or the like, the conductors therein would tend to be flattened and somewhat compressed, reducing the effective cross-sectional area thereof, with a consequent reduction in the safe conducting value of said conductors adjacent the area of juncture within the connector. Additionally, because of the unsymmetrical compacting of a portion of the outer member and inner ferrule resulting from ,the generally uneven radial force applied thereto, the strength of said members would be substantially reduced generally adjacent the area of crimp. Thus, the completed connection would be characterized by an irregularity of retention of the conductors within the connector and a substantial reduction in the strength of the connector itself.

SUMMARY OF THE INVENTION 7 The invention is directed to an improved connector which overcomes the problems noted above with respect to prior art devices by providing a connector having generally concentrically disposed inner and outer members selectively adapted for extrudable deformation about an article disposed therewithin. Positioned within an extrudably deformable preferably electrically insulating outer member is an extrudably deformable preferably metallic hollow inner member adapted to receive'the bared ends of an electrical conductor or the like about which said connector is to be deformed. In practice, the connector is forcibly urged through a preferably progressively restrictive orifice in generally aligned axial relation with the longitudinal axis of said inner member. The connector is thereby subjected simultaneously to a partially radial, partially longitudinal pressure, causing said connector to be extrudably deformed generally longitudinally and inwardly about the article disposed therewithin. The article is thus con strictively secured within the connector substantially along its entire contained length, the outer and inner members of the connector being generally symmetrically disposed about the article therein. Further, the end of the connector directly adjacent that portion of the article protruding outwardly therefrom is extrudably deformed intimately about said article, resulting in a tight seal thereabout. A plurality of similarly or differently dimensioned recesses may be provided in the outer member, each having disposed therewithin a suitably proportioned inner member, to increase the capacity and versatility of said connector. Additionally, the connector may be forcibly urged through varyingly contoured restricted orifices so as to provide selectively different longitudinally disposed configurations about the outer surface of the connector. Each inner member may comprise either a shell-like tubular element, a helically would spring-like element, or a series of interconnected hollow rings. It is therefore an object of this invention to provide an improved connector.

It is a further object of this invention to provide an extrudable connector.

It is another object of this invention to provide an improved connector adapted to be extrudably deformed about the bared ends of a plurality of conductors disposed therewithin.

It is another object of this invention to provide an extrudable connector formed of insulating material to provide an insulating, protective covering over an article disposed therein.

It is still a further object of this invention to provide a connector which may be symmetrically longitudinally extrudably deformed about an article disposed therewithin.

It is still another object of this invention to provide a means for forming a sealed connection.

Other objects and features of the invention will be pointed out in the following description and claims and illustrated in the accompanying drawings, which discloses, by way of example, the principle of the inven tion and the best mode which has been contemplated for carrying it out.

BRIEF DESCRIPTION OF THE DRAWINGS:

In the drawings:

FIG. 1 is a cross-sectional view of an extrudable connector constructed in accordance with the concepts of the invention, including therein the bared ends of a pair of insulated conductors.

FIG. 2 is a cross-sectional view of the extrudable connector of FIG. 1 after extrusion according to the concepts of the invention.

FIG. 3 is a perspective view of the extrudably dcformed connector of FIG. 2.

FIG. 4 is a perspective view of an extrudable connector after deformation in accordance with a further embodiment of the invention.

FIG. 5 is a perspective view of an extrudable connector after deformation in accordance with still another embodiment of the invention.

FIG. 6 is a cross-sectional view of an extrudable connector constructed in accordance with a further embodiment of the invention.

FIG. 7 is a perspective view of the inner member of the connector of FIG. 6.

FIG. 8 is a cross-sectional view of the extrudable connector of FIG. 6 after extrusion and illustrating the engagement therewithin of the bared ends of a pair of insulated conductors.

FIGS. 9, 10, and 11 are perspective views of further embodiments of an extrudable connector constructed in accordance with the concepts of the invention.

Similar elements are given similar reference characteristics in each of the respective drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS:

Turning now to FIGS. 1, 2 and 3, there is shown an extrudable connector constructed in accordance with the concepts of the invention. Connector 20 comprises an extrudably deformable outer member 22 which may be formed of, for example, such non-melt formable plastic material as nylon, polyvinyl chloride, acetal, or polyethelene. A selectively proportioned passage 26 extends generally longitudinally within outer member 22, and communicates with the outer surface thereof at an opening 28. Where necessary or desirable, passage 26 may be suitably modified to extend through member 22 thus providing an opening such as 28 at both ends of member 22. Disposed within passage 26 of member 22 is an extrudably deformable inner member 24, which may be formed from any one of a number of commonly employed electrically conducting materials such as gold, silver, platinum, copper, aluminum, brass, bronze and other suitable metallic materials readily amenable to cold working, the particular choice being dependent at least partly upon the particular application and use contemplated. It will be readily apparent to those skilled in the art that nonconducting metallic or other materials may be employed herein where, for example, the inherent intimate contact between the adjacent conductors disposed within the connector is relied on for electrical continuity. The inner wall of inner member 24 defines an article receiving cavity which may be suitably proportioned to accommodate, for example, the bared ends of insulated conductors such as 32. Longitudinal passage 26 within outer member 22 terminates at a wall portion 48 remote from the first opening 28 of outer member 22, said wall member 48 providing a stop means for the bared ends 30 of insulated conductors 32 disposed therewithin, thereby limiting the insertion of said bared ends within connector 20. Alternatively, passage 26 may be extended completely through the outer member 22, if desired, thus providing an opening such as 26 adjacent both ends of said passage 26, which of course, may further include ancillary stop means appropriately arranged to limit or restrict the insertion of the conductors within the passage. For purposes of illustration, connector 20 is shown in FIG. 1 as having a length A and a height B prior to the deformation thereof. Referring now to FIG. 2, there is shown the connector 20 of FIG. 1 after deformation. Outer member 22 has been partially compacted generally radially inwardly to a dimension D somewhat less than its initial dimension B before deformation, and simultaneously, the longitudinal dimension of outer member 22 has been generally uniformly increased to that indicated as C, somewhat greater than its initial dimension A,by forcibly advancing connector 20 through a preferably successively rcstrictive orifice in a device which, for purposes of illustration, is operable in a manner such as described in my prior pending application for an Extrusion Tool, Ser. No. 867,652, filed October 20, 1969, now U.S. Pat. No. 3,674,392 issued July 4, 1972 and assigned to the assignee of the instant invention, or in my prior pending application for an Improved Extrusion Tool," Ser. No. 27,073, filed Apr. 9, I970, now U.S. Pat. No. 3,614,885 issued Oct. 26, i971 and assigned to the assignee of the instant invention. It will, of course, be readily apparent to those skilled in the art that other suitable devices appropriately structured to effect the desired extrusion may be readily employed herewith without departing from the spirit of the invention. As shown, outer member 22 has been generally uniformly elongated about inner member 24, causing inner member 24 to be similarly elongated longitudinally about the bared ends 30 of insulated conductors 32 disposed therewithin. The longitudinal pressure exerted on bared ends 30 of conductors 32 by the uniform elongation of inner member 24 intimately circumjacent thereto causes the bared ends 30 to elongate generally as illustrated, wherein said bared ends 30 are securely restrained within inner member 24 along substantially the entire length of the inner wall thereof. As further illustrated in FIG. 2, the portion of outer member 22 directly adjacent opening 28 is deformed radially inwardly in restrictive circumferential engagement with the outer surface of inner conductors 32 directly adjacent said opening 28, providing an effective seal therebetween. Thus, after extrudable deformation, passage 26 in outer member 22 is securely terminated at both its ends by an associated closure comprising wall portion 48 at one end thereof, and the seal adjacent opening 28 in outer member 22 at its other end, wherein the bared conductor ends 30 therewithin are desirably protected from adverse environmental attack. Further, the inwardly deformed inner wall 29 of outer member 22 inwardly of opening 28 constrictively engages that portion of the conductors 32 directly adjacent thereto, providing a strain relief therefore, further insuring the retention of said conductors 32 within connector 20. It will be further noted that the height dimension D of connector 20 more closely approximates the overall diameter of conductors 32, thereby providing a close, uniform, compact assembly thereabout.

FIG. 3 is a perspective view of the extrudable connector 20 of FIG. 2 illustrating the resulting generally smooth, uniform contour of outer member 22 after extrudable deformation.

Turning now to FIG. 4, there is shown a further embodiment of an extrudable connector 34 constructed in accordance with the concepts of the invention, illustrating another manner in which outer member 36 may be extrudably deformed through an appropriately orificed restrictive aperture, the inner walls of which have been complementarily shaped with respect to the com tour illustrated therein, to thus form the raised portions 38 and the recessed portions 40 longitudinally disposed about the outer member 36 of extrudable connector Turning now to FIG. 5, there is shown a further embodiment of an extrudable connector 42 further illustrating a manner in which the outer surface 46 of outer member 44 may be extrudably deformed to define a series of generally curvilinear faces, substantially as shown. It will, of course, be readily apparent to those skilled in the art that various modifications and combinations of the shapes illustrated may be employed without departing from the spirit of the invention, and within the concepts herein disclosed.

Turning now to FIGS. 6, 7 and 8, there is shown a further embodiment of an extrudable connector 50 constructed in accordance with the concepts of the invention. Inner member 52, disposed within an outer member 51 is formed of an elongated strip generally helically wound to form a longitudinal, substantially elongated tubular member as best seen in FIG. 7. Although a relatively closely wound member is illustrated, it should be understood that an open wound construction may be effectively utilized in similar fashion. In FIG. 6, the extrudable connector 50 is shown prior to deformation. Disposed within the wound inner member 52 in a manner substantially as described above with respect to FIGS. 1 and 2 are the bared ends 30 of insulated conductors 32. After connector 50 has been extrudably deformed, the inner and outer members 52 and 51, thereof, respectively, are constrictively elongated, sub stantially as shown in FIG. 8. As will be noted, the individual coils of inner member 52 are longitudinally displaced in spaced adjacent relation as a result of the partially radial, partially longitudinal force directed upon inner member 52 by the extrudable deformation of outer member 51 directly circumjacent thereto and in intimate engagement therewith, said coils of inner member 52 being at least partially embedded within the directly adjacent portions of bared ends of insulated conductors 32 and the directly adjacent portions of outer member 51, as at 54, thereby securing said inner member 52 to said outer member 51 and to said bared ends 30 and effecting a secure, rigid retention of said bared ends 30 within said connector 50. Although illustrated as formed of a preferably continuous single elongated strap, it should be understood that inner member 52 may be formed of a plurality of discrete, generally annular elements disposed adjacent one another in axial relationship without departing from the spirit of the invention. Further, it will be readily apparent to those skilled in the art that other selectively predetermined shapes of inner member 52 may be provided to matingly cooperate with similar complementarily contoured longitudinal passages within outer member 51, and that said inner member 52 may be appropriately contoured to provide, for example, either a square, rectangular, or diamond-shaped cross-sectional configuration to increase the biting action thereof, where necessary or desirable.

Turning now to FIG. 9, there is shown a further embodiment of an extrudable connector 58 constructed in accordance with the concepts of the invention. Outer member 60 is formed of a pair of extrudably deformable, elongated portions in adjacent, spaced-apart, aligned relation connected by a web portion 64 therebetwcen. Disposed within each of the individual portions of outer member 60 is an associated longitudinal passage (not shown) terminating at one end of outer member 60 at an associated first opening 62, thus providing a pair of discrete conductor receiving cavities for the insertion therein of the bared ends of insulated conductors or the like.

Turning now to W0. 10, there is shown a further embodiment of an extrudable connector 66 constructed in accordance with the concepts of the invention. As illustrated, outer member 68 is comprised of three extrudably deformable elongated portions, coupled one to another in adjacent, spaced-apart, aligned relation. Longitudinally disposed within each of the portions thereof, in a manner similar to that described above with respect to connector 58 (FIG. 9) is a longitudinal passage terminating in an associated first opening 70 thereof, thereby providing a plurality of openings into which may be inserted the bared ends of insulated conductors or the like for retention therein.

A further embodiment of an extrudable connector 72 is illustrated in FIG. 11. Extrudable connector 72 comprises an extrudably deformable elongated outer member 74 within which is disposed an inner member (not shown) which may be formed similar to member 24 or 52 of FIGS. 1 and 6, respectively. Projecting outwardly from outer member 74 are planar portions 78 longitudinally disposed in complementary relation along the outer surface thereof providing a base portion 80, which may be advantageously employed, for example, to attach connector 72 to a mating support member (not shown) or a further connector (not shown) formed in similar fashion.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

l. A method for securing an extrudably deformable elongate article about a further article disposed therewithin, comprising the steps of: inserting said further article within an article receiving passage in said extrudably deformable elongate article; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformably article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction paral lel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated and compacted radially inwardly, causing the walls defining said article receiving passage to be constrictively disposed intimately about said further article disposed therewithin. I

2. A method for making an electrical connection, comprising the steps of: inserting the bared ends of at least two electrical conductors within a conductor receiving passage in an extrudably deformable elongate article; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction parallel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated and compacted radially inwardly, causing the walls defining said conductor receiving passage to be constrictively disposed intimately about said conductors disposed therewithin.

3. A method for making an insulated electrical connection, comprising the steps of: inserting the bared ends of at least two insulated electrical conductors within a conductor receiving passage in an extrudably deformable elongate article having an electrically insulating material thereabout; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction parallel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated, and compacted radially inwardly, causing the walls defining said conductor receiving passage to be constrictively disposed about said bared ends disposed therewithin.

4. A method of making an insulated electrical connection, comprising the steps of: inserting the bared ends of at least two insulated electrical conductors within a conductor receiving passage in an elongate connector having an extrudably deformable, orificed, outer member formed of electrically insulating material, within which orifice is disposed an extrudably deformable generally hollow metallic inner member, the inner walls of said inner member defining said conductor receiving passage; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction paralled to the longitudinal axis of said extrudably deformable article; wherein said outer member is simultaneously successively selectively elongated, and compacted radially inwardly and intimately about said inner member, causing the inner walls of said inner member to be constrictively disposed intimately about said bared ends of said insulated conductors disposed therewithin. 

1. A method for securing an extrudably deformable elongate article about a further article disposed therewithin, comprising the steps of: inserting said further article within an article receiving passage in said extrudably deformable elongate article; providing a member having a successively restrIctive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformably article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction parallel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated and compacted radially inwardly, causing the walls defining said article receiving passage to be constrictively disposed intimately about said further article disposed therewithin.
 2. A method for making an electrical connection, comprising the steps of: inserting the bared ends of at least two electrical conductors within a conductor receiving passage in an extrudably deformable elongate article; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction parallel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated and compacted radially inwardly, causing the walls defining said conductor receiving passage to be constrictively disposed intimately about said conductors disposed therewithin.
 3. A method for making an insulated electrical connection, comprising the steps of: inserting the bared ends of at least two insulated electrical conductors within a conductor receiving passage in an extrudably deformable elongate article having an electrically insulating material thereabout; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction parallel to the longitudinal axis of said extrudably deformable article; wherein said extrudably deformable article is simultaneously successively selectively elongated, and compacted radially inwardly, causing the walls defining said conductor receiving passage to be constrictively disposed about said bared ends disposed therewithin.
 4. A method of making an insulated electrical connection, comprising the steps of: inserting the bared ends of at least two insulated electrical conductors within a conductor receiving passage in an elongate connector having an extrudably deformable, orificed, outer member formed of electrically insulating material, within which orifice is disposed an extrudably deformable generally hollow metallic inner member, the inner walls of said inner member defining said conductor receiving passage; providing a member having a successively restrictive orifice having an entrance portion and an exit portion, said entrance portion having a dimension greater than the maximum external transverse dimension of said extrudably deformable article and said exit portion having a dimension smaller than the minimum external transverse dimension of said extrudably deformable article; and forcibly advancing said extrudably deformable article through said successively restrictive orifice in a direction paralled to the longitudinal axis of said extrudably dEformable article; wherein said outer member is simultaneously successively selectively elongated, and compacted radially inwardly and intimately about said inner member, causing the inner walls of said inner member to be constrictively disposed intimately about said bared ends of said insulated conductors disposed therewithin. 